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Kinetics Industries, Inc.Manufacturer Of:

One Manufacturer Source Solutions For

Synchronous Motor Field Excitation Systems

• Synchronous Motor Application Questions & Answers

• Specification Regulated Exciter Rectifier

• Specification Solid State Application Circuit

• Specification Contactor Applied Application Circuit

Kinetics’ Plant Location:140 Stokes Ave.

Trenton, NJ 08638Tel: 609-883-9700 Sales ext 122 Fax: 609-883-0025

e-mail: info@kinetics-industries.comweb site: www.kinetics-industries.com

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Synchronous Motor Field Excitation Systems

Table Of Contents For:

Application Question & Answers:

1.Who is Kinetics Industries?

2 . What is the difference between a brush and brushless

synchronous motor?

3 . If I have a brush type synchronous motor; what equipment is

required to operate the motor?

4 . If I have a brushless type synchronous motor; what equipment

is required to operate the motor?

5. What parts of a synchronous motor system does Kinetics

manufacture or have the availability to supply as a full test

/ integrated system?

6. A Generator is similar in theoretical principle to a

synchronous motor; can a generator excitation system be used

on a synchronous motor application?

7 . When applying a regulated excitation rectifier; what

rectifying configuration, 3 or 6 pulse, is “best” for the

highly inductive load characteristics of a synchronous motor

field?

8 . Does Kinetics offer a “small” synchronous motor, functionally

simplistic, excitation package?

9. Can units be supplied as open panels for mounting within

existing enclosures or OEM switchgear line-up enclosures?

10. Can a system be packaged to fit Kinetics offer a package

to fit into a medium voltage switchgear enclosure cell

section? Kinetics cell-in-cell design package.

11. Does Kinetics manufacture solid state field / discharge

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application switching package?

12. Field application contactors vs. solid state application

via SCR switching and latching crow bar circuit.

13. Why does Kinetics manufacture two digital annunciation and

logic modules?

• KinetSync-SR for brush type synchronous motors.

• KinetSync-NB for brushless type synchronous motors.

14. Are systems available that have the capacity to supply

operating data and/or remote operating control via a

computer network information highway?

15. Why is the simple concept of a, KinetSync module to Kinetics

exciter / field application system, inter-connection cable

with plug-in connection an very important Kinetics product

advantage over competitive offerings by others?

16. Can a stand along application panel be supplied for use with

an existing DC power source?

17. How can it be determined if the DC excitation voltage is

being applied at the “correct” time?

18. Why is the wave form observed from a “Small” synchronous

motor discharge circuit not uniform and per the “text book?

19. What is a synchronous motor V-curve pattern?

20. How much power factor correction can be obtained from a

given motor?

21. How is the speed of a synchronous motor determined?

22. What conditions could prevent a synchronous motor from

reaching synchronous speed or pull-up speed?

23. Is there a general “test” procedure to a brushless motor to

determine if a rotating semi-conductor has failed?

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24. Can a Kinetics excitation system be used to regulate plant

power factor?

25. Are systems available for “impulse” loading or extreme

differential of no load to maximum load to no load

applications?

26. Can motor starting lockout protection be included within the

excitation system that prevents damage to the motor

amortisseur winding or squirrel cage winding from excessively

frequent starting?

27. Does Kinetics manufacture retro-fit systems for prime mover

synchronous motors that have a multi-exciter combination field

control system?

28. I have an “unusual” type of synchronous motor; can Kinetics

help me?

29. What “standards”, “codes” and certifications does Kinetics

design and manufactured product to?

30. How are Kinetics’ units designed, manufactured and tested?

31. Product documentation operational maintenance manual and

software provided with Kinetics product.

32. Why purchase a Kinetics excitation system?

33. Kinetics engineering start-up services and training.

34. When comparing quotes & proposals: important standard

features of Kinetics excitation systems.

35. What information is necessary to obtain a quotation?

Caution: Application note concerning brushless synchronous motor

excitation systems – exciter logic must match the operational

logic of the rotating exciter electronics of the motor

manufacturer.

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36. Key commercial contacts at Kinetics Industries.

37. Operation manuals and, drawings.

38. When comparing quotes and proposals; important standard

features of Kinetics’ field application panels.

39. Basic Kinetics SCR regulated exciter specification.

40. Constant potential, diode, exciter with multiple EPT taps

specification.

41. Specification: Contactor applied field application panel.

42 Specification: Totally solid state brush type motor field

application panel & Kinetics’ KinetSync-SR digital

annunciation and logic module.

>> Typical large horsepower, steel mill, rolling mill, brush type synchronous

motor under repair <<

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Kinetics Synchronous Motor Field Excitation Systems

1. Questions & Answers: Who is Kinetics Industries:

Briefly, Kinetics Industries is a USA owned and operated,

integrated, power systems manufacturing company, located in Trenton, New

Jersey. Kinetics Industries was founded as S&M Electric Motor Repair, in

1939 by E. Paul Secrest. The company began as an electrical apparatus

repair and service company for the region’s heavy industrial customers. In

the early 1960’s Kinetics began working closely with “local” heavy

industrial customers to design and manufacture diode rectifiers, SCR

rectifiers and DC motor drives for the retro-fit of motor generator set and

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mercury arc rectifier and new solid state power conversion systems for

plant automation. The company added capacity to manufacture dry type

transformers in the late 1960’s. During the mid-1970’s a complete sheet

metal fabrication facility was added for the manufacture of enclosures,

panels and buss work.

Kinetics’ roots within the motor service industry made the company well

suited to develop rectification products for crane motors, lifting magnet,

traction power system and excitation systems for synchronous machines.

Kinetics has developed experience working closely with various motor

oriented production processes, such as, floor material manufacturers, steel

& aluminum mills, rubber mills, pulp & paper mills and public utilities.

From this heavy industrial experience, Kinetics has grown from a regional

custom manufacturer to a world-wide manufacturer of a product line of

standard and custom DC power supplies, SCR regulated rectifier and field

excitation products for synchronous machines.

Kinetics’ extensive customer list includes a wide spectrum of diverse

industries, utilities, governmental agencies and geographical locations. Our

diverse customer base has enabled Kinetics to develop a product line of power

system products that begins with a basic diode power supply to the

sophisticated facility integrated production process solid state digital

logic and control excitation system for a synchronous motor with data

networking capabilities.

At Kinetics’ single source manufacturing plant located in Trenton, NJ,

Kinetics skilled staff designs and manufactures our own SCR and diode power

control assemblies, dry type transformers from 1 to 2000 KVA, control and

firing circuitry and sheet metal panels and enclosure fabrication. As a self-

contained manufacturing facility, Kinetics brings the team concept to the

manufacturing process. We work to consistently manufacture the highest

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quality power system products and provide the availability of the most

comprehensive and accessible engineering support on the market.

>> Motor pump room at one of the many pumping facilities of Southwest NevadaWater Authority. Pumps driven by 2,500 Hp brushless synchronous motors.Excitation systems incorporate the use Kinetics regulated exciters andKinetSync-NB digital annunciation and control logic modules.

2. What is the difference between a brush and brushless synchronous

motor?

The motor theory and delivery of mechanical power is nearly identical for

both type of motors. The major differences between motors is the method of

“delivery” of the field excitation to the rotating field poles.

• A brush type synchronous motor incorporates the use of brushes riding

against slip rings to deliver the full field current and voltage, power,

field directly to the motor field. The DC power source for field

excitation, field application logic, field application / discharge

resistance application method and field discharge resistors are located

external from the synchronous motor.

• A brushless type synchronous motor incorporates the use of a remotely

located DC power source called a “pilot exciter” or “control power

exciter”. (Common value 125 VDC at 5 to 10 amps DC). The DC “control”

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power source is applied to the motor’s rotating rotor via an induced

electro-magnetic field. The field application logic, power field exciter

and discharge resistors are mounted to the motor’s rotor. By increasing or

decreasing the output of the “pilot” exciter, the rotating power exciter

increases or decreases field strength. The motor manufactures promote that

the elimination of brushes and slip-rings reduces the maintenance

requirements of the motor.

Typical rotating exciter assembly Typical slip ring motor assembly

3. Brush type synchronous motor: what is nee ded to run the motor ?:

1) AC main line power motor starter and / or switchgear.

2) CT's & PT's in quadrature on the AC main power feeds to the motor.

-> Quadrature defined: A quarter of a cycle phase difference. If the angle of

lag or of lead between two sets of alternating current waves be 90’, or a

quarter circle, the waves are said to be in quadrature with each other.

3) A DC power source for field excitation. The DC for excitation can be

supplied from several possible means:

• Common DC mill buss power.

• Motor generator set.

• Synchronous motor shaft mounted DC generator.

• Constant potential diode exciter.

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• SCR regulated rectifier exciter.

4) Field application control and application logic. Old vs. modern methods

• Discrete components consisting of contactors, relays and timers. (Pre

electronic panels)

• KinetSync-SR, solid state, micro-processor based, digital logic and

annunciation control module.

5) Field application method: Two of the common methods are;

• Two normally open poles & one normally closed pole contactors with

over-lapping contacts. Found in “older” vintage packages. Currently

used when excitation power is supplied from a DC buss, constant

potential exciter or existing exciter.

• Solid state field / discharge resistor application via SCR switching

with latching crow-bar circuit. Solid state switching is the most

desirable method of switching and is the modern standard. Solid

state switching application circuits are only available when an

integrated regulated exciter is supplied as a system.

6) Field discharge resistance grid.

7) Application specific features: Kinetics engineering is available to

assist in application customizing features such motor “inching” control

for ball mills and field forcing for steel processing rolling mills.

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>> Typical brush type motor excitation system drawing

>> Typical “complete” excitation system: 5 KV input LBSF, regulated exciter,solid state application circuit, KinetSync-SR annunciation & logic module,discharge resistors all in a NEMA3R line-up enclosure.

4. Brushless motor: what is required to run the motor?

1) AC main line power starter and / or switchgear.

2) CT’s & PT’s in quadrature on the AC main line power feed to the motor.

3) Constant potential or regulated output exciter.

4) For applications where controlling power factor, monitoring the motor,

having a operational history registry or placing operational information on a

communication network Kinetics recommends the KinetSyn-SR digital

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annunciation and logic control module.

>> Typical brushless motor excitation system drawing

5. What parts of a synchronous motor system does Kinetics

manufacture or have the availability to supply with the unit

system ?:

1) Kinetics is the one source solution for the manufacture of excitation

systems and components necessary for "brush" and "brushless" synchronous

motors.

2) Kinetics can either manufacture or supply AC motor starters, of various

types, up to 15 KV class. Components by various major manufacturers

available upon request.

3) Exciter power transformers, EPT: Kinetics manufactures dry type

transformers from 500 KV to 2000 KVA capacity and up to 15 KV class.

4) Exciters for brush type synchronous motors

DC field power sources with regulation closed “on” manufactured by

Kinetics:• Current regulated - feedback loop closed on current.• Voltage regulated - feedback loop closed on voltage.• Power factor regulated - feedback loop closed using a vernier

power factor monitoring circuit.• Remote signal regulated - 0 - 10 volt or 4 - 20 ma control

signal supplied by other to terminal points at the rectifier.

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• Constant potential diode rectifier with voltage adjustment by manual tap adjustment in 5% voltage increments.

5) Exciters for brushless motors• Constant potential diode power supplies.• DC regulators / SCR regulated rectifiers.

6) Solid state, digitally controlled annunciation & logic control modules.• KinetSyn-SR for brush or slip-ring motors.• KinetSyn-NB for brushless motors

7) Field application panel systems for brush type motors by Kinetics:• Contactor applied field application panel system.• Solid state, SCR switching with latch crow-bar circuit field

application panel.

8) Inter-connection wire harnesses shielded cables with quick-connect plugs

for trouble free and highly reliable connections between the exciter /

application panel and the KinetSync annunciation and logic module.

9) Field discharge resistor banks.

10) Data information highway interfacing.

11) Application specific features and parameters of operation.

12) Open panel construction for mounting within the customer’s enclosure or

Kinetics manufactured NEMA1, 3R, 4, 4X or 12 enclosure.>> Brush type synchronous motor excitation system for a 5,000 Hp water pump atelectrical utility generation plant; 5 KV LBSF, regulated exciter, solid stateapplication panel, KinetSync-SR annunciation logic module, discharge resistorsin a NEMA4 enclosure.

6. A generator is similar in theoretical principal to a synchronous

motor; can a generator excitation system be used on a synchronous

motor?

Briefly, the designers of synchronous motors have the criteria of delivering

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mechanical load to a process as the paramount ultimate objective. Stating the

obvious, a synchronous motor rotor is designed around the shaft to deliver

mechanical load. A generator rotor is designed with the object of generating

electrical power into a power grid. Although a synchronous motor can be run

continuously with a leading power factor to act as a generator, the performance

will always be marginalized when compared against generator specifically

designed as electrical power generator.

The same engineer principles hold for excitation systems. A generator

excitation will “work” but a generator excitation is designed for the

generation of power, regulating the quality of the power generated and

synchronizing the generated power to a power system grid. A synchronous motor

excitation system circuitry is designed for the production of dependable

mechanical work through the motor shaft.

7. When applying a regulated excitation rectifier, what rectifying

configuration, 3 or six pulses, is “best” for the highly inductive

load characteristics of a synchronous field?

In motor drive applications the usual consideration for using a six pulse

or even 12 pulse, rectifier over a three pulse hybrid bridge (three SCR’s and

three diodes) is faster response time and lower semi-conductor ripple on the

rectifier output buss. A synchronous motor field application is highly

inductive and is a different type of load from a “motor drive” type of load.

The highly inductive nature of a synchronous motor field makes the need

for “fast” response a moot issue. The faster response of a 6 or 12 pulse

system vs. a 3 pulse system can be a detriment to the excitation system

performance. The field’s current changing time constant, usually measured in

seconds, is quite long in comparison to a SCR control response time that is

measured in milliseconds and moving to “faster” regulator response can cause

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system instability. For synchronous motors, “slowing” the SCR control

response time to match the motor’s rotational inertia time characteristics

while maintaining system “stability” is an application design parameter.

Due to the inductive nature of the synchronous motor field, it becomes

almost essential to utilize free wheeling or commutating semi-conductors

across the load to minimize current ripple. The three pulse system does not

require the commutating device to function. A six pulse system does not

require the commutating device to function but without it the field current

ripple becomes very onerous as the rectifier voltage can actually reverse and

produce regenerative effects with “high” ripple voltage and current spikes.

For exciters being applied to the motor field through power contactors, a

3 pulse exciter rectifier is normally selected due to its cost effectiveness,

lower current ripple to the motor field, lower complexity and reduced number

of components. Six and 12 pulse systems are utilized when special functions,

such as negative field forcing, rectifier output reversal or solid state SCR

switching is applied to the rectifier output. Note: Kinetics’ solid

state field application system with SCR switching and latching

crow-bar circuit incorporates the use of a six pulse SCR

regulated exciter package.

8. Does Kinetics offer a "small" synchronous motor, functionally simplistic,

excitation package ?:

For "small" synchronous motors, non-critical operations or customer's

desiring the least expensive means of synchronous motor field application;

Kinetics does offer a combination tapped transformer / diode rectifier, motor

ramp to synchronous speed timer and field application / discharge resistor

contactor package, Kinetics model type SYNPTS . DC field voltage adjustment is

by the manually changing of taps on the diode rectifier isolation

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transformer.

A Full current capacity field rheostat is available as an option for

manual on-line DC voltage adjustment. If the option of field voltage

adjustment by a rheostat is being considered; Kinetics recommends that a SCR

regulated rectifier, model type SVRS , also be considered. In many cases a SCR

regulated rectifier is less expensive then a rheostat when cost factors such

as delivery lead times, energy consumption, maintenance and operator

attention for voltage adjustment are factored into the comparative cost

analysis.

The most basic of field excitation packages, Kinetics model type SYNPTS ,

assumes that the motor's synchronous speed has been achieved when the timer

has timed out and the DC field is applied. In the event of a system problem;

the motor starter protective relays or overloads must be relied on to trip

the system off line.

System status annunciation, motor life protection features and motor

performance adjustments are not available with a functionally basic, SYNPTS

type of system. Kinetics recommends the performing of a "down side" risk

analysis when applying a first cost functionally simplistic system such as a

SYNPTS vs. a SYNCHAPP-C or SYNCHAPP-SS with a KinetSync annunciation & logic

system that offers motor and AC power system disturbance protection features.

>> Typical “simplistic” panel for mounting in customer’s existing switchgearenclosure. Contactor applied system. Minimal annunciation – first costpurchase package.

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9. Can units be supplied as open panels for mounting within existing enclosures

or OEM switchgear lineup enclosures ?:

Kinetics has a complete sheet metal fabrication department at our Trenton,

NJ plant to package open panel systems into the applications available space

constraints. A very important feature of Kinetics’ open panel excitation

package with our KinetSync module product offering is our exclusive inter-

connection cables with quick connection plugs. Kinetics’ shielded, color

coded, cables substantially reduce installation time and the possibility of

wiring errors.

Units provided in enclosures can be supplied with the same space

variability and in NEMA classifications: 1, 2, 3R, 4, 4X and 12.>> Pictured below: 350 ADC at 125 VDC regulated exciter, solid state field

application package, KinetSync-SR digital annunciation and logic controlmodule and interconnection wire harness with quick connect plugs.

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10. Can a system be packag ed to fit into a “standard” medium voltage

switchgear enclosure cell?

>> Kinetics’ Cell-in-Cell excitation package, KinetSync-SR annunciation &logic module and inter-connection wire harness with quick connect plugs.

Kinetics has designed a space economical package we have termed “Cell-in-

Cell”. The package unit includes: medium voltage input fuses, EPT transformer,

SynchApp-SS exciter / application panel, inter-connection cables and KinetSync-

Sr annunciation & logic module. The Kinetics cell unit is delivered to the

customer ready to slide into the customer’s switchgear cell. The Kinetics’ cell-

in-cell package provides the customer with the fastest an lowest installation

cost retro-fit package available.

11. Does Kinet ics manufacture a solid state applied field application panel?

Kinetics began manufacturing our first solid state field application

packages in the early 1980’s. The units have proven to be highly reliable and

far more desirable then mechanically linked contactors. The Kinetics model

type SynchApp-SS incorporates the use of a power semi-conductor switching

configuration and latching crow-bar circuit to provide a "solid state field

application contactor" system. The SynchApp-SS is a 100% solid state system.

The SynchApp-SS is only available as a packaged system in combination with a

Kinetics SVRS regulated rectifier. Today, operating engineers and technicians

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tend to be quite comfortable with power semi-conductors and gate firing

circuitry. Kinetics’ SCR switching circuit has been designed and constructed

to be serviced in the field. The system does not use “specialty” or difficult

to locate components that would result in extended down-time should a

component fail.

Inter-locking electro-mechanical contactors for field and discharge

resistors have the disadvantage of being expense, long delivery lead times,

produce corrosive off-gases from arcing and require significant panel space

vs. SCR switching built into the output side of the solid state regulated

exciter.

The majority of exciter & field application packages that Kinetics

manufactures today are of the 100% solid state design.

>> One of fives, 100% solid state excitation systems, manufactured by Kinetics,for a large paper mill and installed on 6,000 Hp “grinder” motors.

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12. Field application contactors vs. solid state application via SCR switching

and latching crow bar circuit.

A common point of misunderstanding concerns synchronous motor excitation

systems is the selection of a field application method. If a product

offering is selected from an on-going and regular manufacturer of

synchronous motor excitation systems; the proposed product will be a system

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specifically designed for a brush type synchronous motor; the

specification of a field application method is rather straightforward.

All the leading manufacturers of synchronous motor excitation systems in

the United States, promote the use of solid state SCR switching and advise

against using contactors as the field applications when a new regulated

exciter is being supplied.

As a commercial note: system integrators and manufactures of generator

exciters or DC motor drives commonly advocate using field contactors because

contactors can purchased and installed on the output of a rectifier, DC

motor drive or generator exciter. The contactor method must be used because

these companies have not invested in the product development engineering

necessary to integrate an SCR switch circuit into a regulated rectifier or

motor drive.

For applications using a common DC buss, MG set, diode rectifier,

regulated rectifier or existing DC power source; field contactors must used.

The redundancy of contactors with a solid state SCR switch is not a

practical or technically feasible design configuration and should not be

used.

DC field breakers are used in generator system applications and are not

suitable for synchronous motor applications due to cost of a three pole

field breaker in relation to SCR switching, relatively slower switching

speed and the mechanical fatigue due frequent stopping and starting.

13. Why does Kinetics manufacture two digital annunciation and logic modules

for synchronous motors?

• KinetSync-SR for brush type / slip rin g synchronous motors

• KinetSync-NB for brushless synchronous motors

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For we designed our digital annunciation and control logic module, we asked

our customer what they what in a system. The overwhelming request was for two

units; one pre-programmed for characteristics of brushless motors and one

pre-programmed for the operation characteristics of brush type motors.

The two unit approach offers:

• Reduced programming and learning curve time by engineers and

technicians. KinetSync units come program ready for installation to

motor’s excitation system.

• Less confusion by installers and users understanding the product and

features. The installer does not deal with sorting out which

features apply to a given type of motor.

• Reduced cost: non-applicable features and circuitry were not

required to be purchased in a one size fits all package.

• Greater product hardware and programming flexibility due to the

modules being designed for the unique characteristics of the two

motor types.

• Operational instruction manuals are easier to use and understand.

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14. Are systems available that have the capacity to supply operating data and/or

remote operating control via a computer network information highway?

Kinetics is continually working to provide systems that are state-of-the-

art with the rapidly changing computerized plant automation systems. Kinetics

does offer interface capabilities with several of the "major" data highway

system manufacturers. All KinetSync annunciation and logic modules come with

RS232 and RS485 ports. Communication output of operation status and input of

operating parameter adjustments via interface ports are standard features of

the KinetSync-SR and NB modules. For current specifics on data highway

interfacing; contact your Kinetics sales representative.

15. Why is the simple concept of a KinetSync module to the Kinetics exciter /

field application system inter-con nection cable with plug-in connectors such an

important Kinetics product advantage over offerings by “others”?

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>> Kinetics exclusive wire harnesses. Photo on right shows connection of thewire harness plugged into the KinetSync. KinetSync mounted in a drawout carriageassembly

From our years of manufacturing experience of open panel systems; we have

all to often serviced customers that had unit operational problems due to

inter-connection wiring errors between the enclosure door mounted KinetSync

and the exciter /application panel. Installation wiring errors due to lack of

familiarity and the inability to test the wiring in the field increase the

cost of installation and can result in damaged equipment. To eliminate the

potential of wiring problems; such as missing wires, reversed polarities or

wires to incorrect terminals, Kinetics developed a shield inter-connection

cable with Molex quick connect plugs.

The Kinetics manufactured inter-connection wire harnesses are continuity

tested for customer quality control assurance.

Kinetics is the only excitation system manufacturer to supply inter-

connection cables with the product as a standard feature.

The cables provide the customer the following benefits:

• Maintain component testing integrity from Kinetics synchronous motor

test stand to the using customer’s final operational location.

• Reduced product installation wiring time.

• Reduction of front-end time to determine wiring requirements.

• Shield cables provide protection of “signal” integrity.

• Plug connections ease KinetSync and/or exciter / application panel

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change-out for quick servicing and minimizes down-time.

16. Can a stand-alone application panel be supplied for use with an existing DC

power source?

>> Contactor applied field system for operation off a customer’s existing DCplant buss.

Yes. Kinetics manufactures a contactor applied field application panel

system for this type of project. Kinetics’ model SynchApp-C was designed for

applications using existing excitation power from a common DC mill buss, MG

set, constant potential diode rectifier or regulated output rectifier. The

SynchApp-C system is the correct application panel for systems using

rectifiers manufactured by a supplier other then Kinetics.

17. How can it be determined if the DC excitation voltage is being applied at

the “correct” time?

One method, to determine if the field is being applied at the correct

time, just below synchronous speed, is to connect a recording oscillograph

across a portion of the field discharge resistor to obtain a tracing of the

field discharge current during motor start-up. The “slip frequency”, the

frequency of the voltage induced onto the motor field by transformer action,

decreases as the motor RPM increases. At synchronous speed this frequency

will be essentially zero. The tracing shown in figure 17.A is a typical wave

form of a properly timed application of the DC field to the motor.

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Caution - Safety consideration: Dangerously high voltages can bepresent on the field discharge circuit while the motor is ramping upto synchronous speed. Voltages of 3500 to 4000 volts are notuncommon. Proper safety, insulation pre-cautions and procedures forhigh voltage metering must be implemented prior to motor starting.

>> Figure 17.a Field applied after motor has reach “pull-up”

speed <<

The voltage and current amplitudes across the field discharge circuit

will, for most synchronous motors, increase as the motor speed increases.

When the motor reaches its “pull up point” or maximum non-synchronous speed,

the current across the field discharge current will drop precipitously. This

point is typically in the 2 to 1 hertz slip frequency range. At this point,

the motor has achieved the optimum synchronization point and the field can

be applied with the minimum power circuit disruption.

If the field is applied before this optimum synchronization point is

achieved, the motor attempts to “pull up” in speed and into synchronization

when its slip frequency is too high. The motor’s rotor attempts to rapidly

increase in speed causing a potentially destructive induced voltage spike

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back across the motor’s slip rings, through the brushes and into the DC

field power source. This power spike is referred to as “flashing the rings”

– a well selected term to describe the dramatic arc & flash produced when

the spike travels across the slip rings to the brushes. Flashing the field

can cause significant arc damage to rings, brushes, brush-holders and the

exciter system. In most cases, a substantial AC power disturbance will also

occur when the field is applied to early. The motor will attempt to

accelerate to synchronous alignment, thus drawing high AC in-rush current

type loading.

>> Figure 17.b. Field applied prior to synchronous speed <<

The sample oscillograph, figure 17.b., shows a classic peak waveform with

the motor field being applied prior to the motor having reached “pull up”

or maximum non-synchronous speed. The denoted “glitch” in the waveform is

the point where the DC field excitation voltage is applied to the motor

field prior to the motor having reached synchronizing speed. The motor

attempts to pull up to synchronous speed instantaneously. The attempted

rapid acceleration forward of the motor combined with the injection of DC

acting upon the remaining AC component from the less then synchronous speed

transformer action of the field, causes the peaked wave shown on the

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oscillograph. The peaking voltage in the illustrated oscillopraph is nearly

double the sinusoidal voltage prior to the excitation being prematurely

applied.

18. Why is the wave form observed from a “small” synchronous motor discharge

circuit not “uniform” and smooth as per the “textbook” and shown in 17.a?

Relatively small synchronous motors will accelerate rather quickly. The

wave form will include; power system distortions due to motor in-rush, rotor

and shaft mechanical inertia distortions and uneven motor acceleration. The

wave form in figure 14.a is from a 22,500 HP motor with a acceleration time

of nearly 30 seconds. A common waveform for a 500 to 1,000 HP motor would

appear as show in figure 15.a. The acceleration slip frequency waveform show

occurs over 3 seconds. The field is applied at the correct time. Note there

is no peaking or waveform distortion is present after the field is applied.

>> Figure 18.a “Small synchronous motor slip frequency & correct

application <<

19. What is a synchronous motor V-curve pa ttern? Per Audel – Electric Motors by

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Edwin P. Anderson and Rex Miller.

In the case of a synchronous motor pulling a constant load, a

variation in the field current is followed by a variation in the stator current,

giving the V-curve pattern. For a given load, there is a single value of field

current that will give unity power factor at the motor terminals. Increasing or

decreasing the field current from this value will give a power factor less than

unity – increasing the field current will give a leading power factor, and

decreasing the field current will give a lagging power factor. Stated another

way, for a given load with constant voltage, if the field current is changed

either way from the unity power-factor value, reactive current will be produced,

causing the line current to increase, as shown by the V curves in the diagram

below. This reactive current will be leading if the field excitation is

increased, or lagging if decreased.

20. How much power factor correction can be obtained fr om a given motor?

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The motor manufacturer develops a set of performance curves based on

the design relationship of the rotor field to the stator. As a general guide the

curves below with basic equation will give a general indication of leading

reactive KVA in percent of rated HP of the motor vs. percentage of motor

loading.

21. How is the speed of a synchronous motor determined?

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The speed of a synchronous of a synchronous motor is determined by the

frequency of the supply current and the number of poles of the motor. Thus, the

operating speed is constant for a given frequency and number of field poles. All

motors are built with an even number of poles. The equation for the

determination of motor speed is:

Revolutions/min = frequency * 120 / poles

22. What conditions could prevent a synchronous motor from reaching synchronous

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speed or pull-up speed?

Failing to reach synchronous speed and extended operation of the

motor below this level, without the field applied will cause significant

damage to the motor. The motor manufacture will specify the maximum time

that the motor can operate from the amortisseur winding and below

synchronous speed. A timer function within the excitation system should

always be present to prevent extended operation and motor damage.

Common causes of the motor not accelerating to synchronous speed:

1) Open field circuit / incomplete circuit due to no exciter power to the

field. Possible causes: problem with the exciter, loose cable to the

field or brushes not making contact to the slip ring.

2) Open or shorted field windings.

3) Extended AC main power line voltage drop.

4) Excessive mechanical load greater then the squirrel cage or amortisseur

winding has capacity to carry. The majority of synchronous motors are

designed to start with “no-load”.

5) Mechanical problem with the motor.

23. Is there a general “test” procedure to a brushless motor to determine if a

rotating semi-conductor has failed?

The majority of the excitation system of a brushless synchronous motor

is mounted on the rotating rotor shaft. Some synchronous motor manufactures

do have visible annunciation lights on the rotating exciter to indicate an

open semi-conductor. There tends to be a reluctance to accept a rotating LED

indication as a definitive reason to open up these rather large motors for

time consuming service. It is only natural, for there to be a desire, for

the source of a problem to be “of motor” and not “believe” the indication of

rotating LED’s. To address this operator / user desire to have a cross check

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– and more definite direction to the source of a motor problem; Kinetics

developed a circuit that can be added to exciter to detect unbalanced semi-

conductor ripple injected back into the exciter when a rotation semi-

conductor is not function. By detecting the irregular semi-conduct ripple,

this optional circuit feature, provides the user higher level of confidence

towards expeditiously locating the source the “problem”.

24. Can a Kine tics excitation system be used to regulate plant power factor?

If a synchronous motor is of significant size in relationship to the

overall plant electrical utility load; the motor can be used to regulate

plant power factor by the generation of VARs when the motor is operated with

a leading power factor. A Kinetics SCR regulated excitation rectifier with

the feedback loop closed on plant power factor can be provided that will

produce VARs back into the system to improve or regulate overall plant power

factor.

Potential application limitation: A synchronous motor has a fixed

capacity; a combination of electrical VAR generation and mechanical output.

The sum of the parts will equal a total capacity for a given motor. Plant

power factor can be regulated within the differential limit of the overall

motor capacity and the load requirement to drive the designated mechanical

load. When operating a synchronous motor with a leading power factor for VAR

generation, the VAR vs. mechanical load must be balanced within safe limit

so as to not overload the motor. To prevent the potential of overloading the

motor due to the combined sum of VAR generation and mechanical load

exceeding the available KVA capacity of the motor; Kinetics strongly

recommends incorporation of a Kinetics minimum / maximum excitation limiter

circuit into the rectifier regulation control circuitry.

25. Are systems available for impulse loading or extreme differential of no load

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to maximum load to no load applications?

Yes. Kinetics offers systems with field forcing capacity and maximum load

to minimum load / no-load protection.

As a brief variable loading / impulse load example; a common rolling mill

application in a steel mill, is for a motor to be running lightly loaded

when product is not in the mill. When a bar is fed into the mill, the motor

first sees an impulse of loading and then loading tends to be relatively

constant. As the end of the bar reaches the mill stand; the end of the bar

may have cooled and be harder to roll. The exciter / motor system respond by

providing an "over-voltage" to the field, forcing the field, for a short

time duration in order to provide the additional torque required to pass the

harder material through and out of the mill. As the bar exits the mill the

Kinetics field regulator must quickly respond by phasing back to protect

against motor "overshoot" and the pulling out of synchronization as a result

of the motor going from maximum loading with a forced field to a minimal

loading / no-load and waiting for next bar status.

Kinetics has manufactured power factor regulated excitation systems for

impulse and variable motor loading applications. Briefly, the excitation

regulation is a combination power factor and voltage regulated feedback loop

system that limit system range by Kinetics' signal summing circuitry that

includes a minimum and maximum time intervals for system response and

voltage excursion limits.

For information on impulse or variable motor loading application, contact

Kinetics' sales engineering at 609-883-9700 extension 122 or your local

Kinetics' sales representative.

26. Can a motor starting lockout protection be provided within the excitation

34

system that prevents damage to the motor amortisseur winding or squirrel cage

winding fro m too frequent starting?

As a "standard" programming feature within Kinetics' SYNCHAPP-C and

SYNCHAPP-SS field application panel micro-processor logic controllers are a

series of commands that lockout the AC motor starter from attempted motor

re-start for a programmed dwell time interval. The dwell time interval is

determined by the motor manufacturer's designed operational specification. A

motor's operational instruction manual should provide a recommended dwell

time between attempted starts. A dwell time between motor starts is a very

important motor protection feature in that it reduces the potential of

damage or burnout failure of the motor's amortisseur winding due to the

winding's service factor being exceeded as a result of excessive attempted

motor starting. The dwell time between starts is one of the many motor life

protection features designed into Kinetics' synchronous SYNCHAPP-C and

SYNCHAPP-SS motor field excitation systems.

Example: 500 Hp motor: dwell time set at 30 seconds between attempted

starts.

As an optional system feature; Kinetics offers additional micro processor

logic circuitry and system programming that permit the setting of limits on

the number of starts over a time interval. The number of attempted motor

starts per time interval limit feature reduces the risk of amortisseur

winding failure due to the winding service factor being exceeded due to too

frequent attempts at motor starting over a maximum time period. Kinetics

recommends the addition of the maximum start per time period feature for

motors 5,000 horsepower and larger.

Example: 10,000 Hp motor: 10 minute dwell time between attempted starts and

a maximum of 3 attempted starts over a one hour time period.

27. Does Kinetics manufacture retro-fit systems for prime move r synchronous

35

motors that have a multi-exciter combination field control system?

Kinetics has the technical expertise and installation experience to

provide several option proposals for the retro-fit of multi-exciter

combination systems. A common multi-exciter would consist of; a "small"

rotating regulating exciter set, (Kinetics refers to this type of exciter as

a pilot exciter.), that excites and controls the field on a power amplifier

rotating exciter set, that in turn excites the field on a "large" primary

mover synchronous motor.

As an application example; a steel rolling mill has a 25,000 horsepower

motor running a roughing mill stand. A 1 Kw pilot exciter is mounted on the

shaft of the 25,000 horsepower motor. The pilot exciter excites the field on

a 125 Kw rotating, MG set, exciter, that in turn excites the field of the

25,000 Hp synchronous motor.

Kinetics can manufacture a retro-fit package for only the pilot exciter

or only the power amplifier exciter or a completely "new" excitation system

that retro-fits both the pilot exciter and the power amplifier exciter.

A Multi exciter system and / or the marrying of rotating exciters with

their physical constraints of rotational inertia time delays, with the near

instantaneous response of solid state regulated exciters requires a unique

control scheme to provide a stable and reliable motor control system.

Kinetics has the technical personnel, factory testing facilities and

installation experience for multi-exciter system retro-fit projects.

Solid state excitation systems can be provided that retro-fit only the

pilot exciter, retro-fit only the power amplifier exciter or both the pilot

exciter and power amplifier exciter.

28. I have an "unusual" type of synchronous motor , can you help me ?

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Kinetics hopes we can; we have attempted to develop a wide range of

knowledge on "special" purpose motors such as a dual speed consequent pole

configuration, high starting torque wound rotor configuration switched to a

synchronous motor winding configuration once the motor is up to synchronous

speed and reverse directional rotating stator motors.

Kinetics' goal is to be specialists on all types of synchronous motors

systems to best serve all our customer's synchronous motor excitation system

applications.

29. What standards and codes do Kinetics manufactured units meet or exceed ?:

Transformers, rectifiers, control panels, electronics and wire sizing and

techniques, will meet or exceed all applicable NEMA, ANSI, IEEE, JIC, OSHA,

EPA, NFPA and CSA standards and codes.

Kinetics is a U.S. Department of Labor and State of New Jersey approved

apprenticeship facility for the electrical / electronic and sheet metal

fabrication trade skills.

The KinetSync-SR and KinetSync-NB logic and annunciation modules are UL

and CUL Listed products.

>> Units supplied to European steel mill for slip ring motors requiring 500 ADCat 50 VDC excitation. Systems included Kinetics regulated exciter with solidstate field application, KinetSync-SR digital logic and annunciation module anddischarge resistors. Unit tested and certified by Kinetics to CE and CSAstandard for steel mill application in Italy.

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30. How will the excitation system be tested ?:

All exciters are load tested by a highly inductive reactor bank to

simulate the inductive field characteristics, including spikes and surges

associated with the collapsing field of a synchronous motor.

Kinetics' field application panel systems are tested by operation of one

of several synchronous motors within Kinetics' operational / loading testing

facilities.

Standard testing of Kinetics' manufactured transformers include: high

potential test, open circuit ratio test, excitation and short circuit

regulation tests. Testing will conform to ANSI/IEEE standards C57.12.01 for

dry type transformers.

Kinetics welcomes customers to visit our plant to witness the operational

testing of their order prior to shipment. Kinetics does not charge a fee for

customers to witness product testing.

31. Product documentation, operational maintenance manuals and software provided

with Kinetics product.

Kinetics engineering department is committed to supplying operational

manuals that are useful to all level of users, comprehensive in information

and user friendly. All manuals include; system & circuit descriptions,

installation instructions, parameters of operation settings, enclosure or

panel mounting / installation drawings, component layout / location

drawings, system drawings, circuitry drawings, trouble shooting guide, parts

list with recommended spare parts.

Manuals and drawings are available in electronic format upon request.

Kinetics maintains an engineering library on all systems we have

manufactured back to the early 1960’s. Replacement manuals are available for

a minor fee to cover retrieval, reproduction and handling costs.

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32. Why purchase a Kinetics excitation system?

1) From Kinetics' founding in 1939 as a motor maintenance company, we have

stayed focused as a "motor oriented control manufacturer".

2) Kinetics is the only one source solution manufacturer, manufacturing all

the critical component sections of an excitation system specifically

designed and rated for synchronous motor field excitation. Kinetics takes

the design, manufacturing, test, documentation and servicing responsibility

for the critical elements in-with a chain of a complete excitation system.

Kinetics manufactures, under one roof, all our own transformers, control and

SCR firing circuitry, sheet metal enclosures or open panels and power semi-

conductor rectifying assemblies. Being an integrated manufacturer enables

Kinetics to keep strict control of the products design parameters, assembly

workmanship, testing and engineering startup support.

3) We listen to your application specifics. Our manufacturing concept is to

remain flexible in the systems we design in order to meet the parameters of

operation for the customer's application.

4) Kinetics designs our products to be flexible. Kinetics strives to match

the scope of a customers project objectives with the level of product

offering. Kinetics’ products are designed to offer customers the option of

integrating system segments with existing segments or segment products

offered by other suppliers.

5) Kinetics offers customers open access to our design and product support

engineering staff.

6) Kinetics is an awarding winning and established power systems

manufacturing company. Kinetics began manufacturing motor oriented power

rectification products in the early 1960’s. In 1995 Kinetics' dedication to

product and organization excellence was recognized when Kinetics was

selected as a "New Jersey Top 20 Growth Company".

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7) Kinetics excitation system experience of successful projects covers a

wide range of customer types, industries and application environments.

Customer references and testimonials are available upon request.

>> Complete excitation system with power factor correction regulation andcustomer request motor protection / switchgear relays. One of several unitsinstalled on reciprocal compressors at an automotive engine foundry compressorroom

33. Kinetics engineering start-up services and training.

Kinetics has a staff of factory engineers available for start-up and

training classes at a customer’s location.

Our engineers may also be contracted for field engineering services or

P&M work on Kinetics manufactured systems out of warranty.

Please contact Kinetics for a quotation and a copy of our established

published rate sheet.

>> Photo show two of six 800 Hp brushless synchronous motors in a waste waterroundhouse. Pumps motors are operated in pairs; one motors is a fix speed pumpsecond motor incorporates an eddy current clutch for adjusting pump output. As aretro-fit project to the existing obsolete control, Kinetics manufactured newexcitation that included digital communication and new eddy current clutchregulated rectifiers.

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34. When comparing quotations and proposals; important standard features of the

Kinetics excitation system.

1) How many different manufacturers are involved in the various excitation

system segment? Kinetics is the only manufacturer who directly designs and

manufactures all the critical system segments.

2) Who will service the product and each system segment? A Kinetics product

system requires Kinetics to be 100% responsible for all service and

product support.

3)Who controls the operational logic software? As a one source solution

manufacturer, Kinetics is responsible to the customer for maintaining

support of software, micro-processors, bridging hardware and software

transfer from one generation to the next and technical product support for

past and present systems.

4) Are you getting a “bucket of parts” or a manufactured product with the

details covered that minimize installation cost, time and potential for

“problems”? A prime example is Kinetics’ exclusive interconnection wire

harnesses.

5)Has an EPT been included and has the EPT been designed and manufactured

for regulated rectifier duty? Since Kinetics has manufactured all our

rectifier transforms in the 500 VA to 2000 KVA range for 40 years, you can

be assured of a properly designed and manufactured EPT.

6) Is the system being proposed specifically designed for the application of

a synchronous motor field excitation system? DC motor drives, discrete

component panelboards and generator exciters may function but offer

marginalized solutions because these products have not been specifically

designed for the specific parameters of operation of a synchronous motor’s

highly inductive load field with the demands of mechanical work load.

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35. What information is necessary to obtain a quotation :

The minimum data Kinetics' application engineers require to initiate a

proposal is the following:

1) Application that the motor is operating within.

2) Is the motor a "brush" or "brushless" field type of

synchronous motor.

3) Section(s) of the motor control / excitation system that

are required for the project.

ie. motor starter, field exciter, field application

panel in a common NEMA1 enclosure.

4) If a motor starter is required, method / type of motor

starter desired and is the motor starting at full volts,

reduced voltage or under a load.

5) Horsepower of the motor.

6) AC input voltage to the motor.

7) AC input voltage available for the exciter.

8) Field excitation DC voltage and amps.

9) Desired mode of exciter regulation feedback

loop closure: volts, amperes, power factor, VAR's

remote signal or none and intend to use a diode power

supply or common DC bus?

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10) If the inquiry includes a field application panel; what

is the field discharge resistor bank ohmic value

specified for this specific motor or the what is the

value of the existing resistor bank?

11) Type of enclosure or open panel and any space

constraints.

12) Any other motor or system data readily available such

as; nameplate data, a system schematic or motor design

data.

36. Commercial contacts to receive an application proposal:

Sales contact can be made to either the local sales representative or call

Kinetics Industries directly at 609-883-9700 sales extension 122.

Sales fax: 609-883-0025

E-mail: info@kinetics-industries.com

Wed site: www.kinetics-industries.com

Shipping, mailing & UPS address: 140 Stokes Ave.

Trenton, NJ 08638

37. Operation manuals & drawings:

Standard operation & maintenance manuals include; feature descriptions,

installation instructions, terminal point layout interconnection diagrams,

system startup procedure, electrical system drawings, enclosure footprint

drawings, circuit board schematics with component values, trouble shooting

guide and a parts list with recommended spare parts. Kinetics will provide

two manuals per unit in water resistant covers unless specified otherwise

at the time of unit / system quotation.

Unit installation and startup can be a significant cost percentage of a

43

excitation project. Being sensitive to this economic fact; Kinetics'

includes in our operation and instruction manuals a section with specific

information for the equipment installer to assist in an expeditious

equipment installation, interfacing with surrounding equipment, unit

checkout prior to startup and the system startup.

38. When Comparing Quotes And Proposals; Important Standard Features Of

Kinetics' Field Application Panel :

1) Kinetics' SYNCHAPP-C and SYNCHAPP-SS systems have the very important

feature of providing "impending pullout of synchronization protection". By

using the signals from the AC motor starter CT's and PT's; Kinetics' field

application panel systems sense that a motor is pulling out of

synchronization and shuts the motor down BEFORE the pull out of

synchronization is completed. Pulling out of synchronization can cause

damage to the motor and will produce significant disruption to the

associated power system.

2) Kinetics' systems are "confirmed system status" operational. Kinetics'

application panel systems continuously monitor / check for confirmation

signals that all parameters of operation are functioning properly prior to

motor startup, field application and in proper "running" condition.

Kinetics' SYNCHAPP-C and SYNCHAPP-SS systems do no t apply the field

"blindly" after a fixed time interval under the assumption that the motor

"should have achieved synchronous speed" or "after the fact" tripping of a

switchgear type relay.

3) Kinetics' regulated rectifier exciters can be offered with either a

"soft" ramping on of the output to the motor field upon application or a

"hard" instantaneous full field voltage application. The ramping on of the

exciter voltage after application provides a gentle pull into

44

synchronization. "Soft" pull into synchronization is another feature within

Kinetics system that is designed to protect the life of the motor and

minimize power system disturbances.

39. Basic Kinetics SCR Regulated Exciter Specification:

Kinetics model type SVRS

The Kinetics SVRS regulated output rectifier is a closed loop, solid state,

fully controlled phase shifted, limited range, DC power supply specifically

designed and rated for the demanding inductive loading characteristics of

synchronous motor fields.

The feedback regulation loop of the SVRS is available with the loop closed on

current, voltage, power factor or a remotely supplied control signal. The mode

of regulation needs to be specified at the time of order.

The SVRS rectifier is designed to provide an economical and efficient means

of converting AC power to DC power within a limited operating range of 80% to

110% volts at 100% current. Below 80% volts the units current capacity is

reduced directly proportional with voltage reduction. 110% to 100% output

voltage capacity is provided to accommodate low AC input voltage of up to -10%

without loss of full rated output capacity. Units are available with extended

ranges; below 80% and over-voltage field forcing with protective timed interval

circuit.

The 100% current between 110% to 80% voltage capacity range is designed into

the SVRS rectifier to comfortably handle the essentially constant impedance load

of a synchronous motor field.

Standard excitation rectifier is a three pulse, SCR - diode hybrid bridge

rectifier circuit with a free wheeling or commutating diode for low current

ripple output. 6, 12 & 24 pulse systems are available for applications that

45

require "tighter" regulation and or DC output with a lower semi-conductor ripple

content.

Standard Parameter of Operatio n:

Design and Standard Codes: Transformer and rectifier system will meet or exceed

all applicable NEMA, ANSI, NEC, JIC, OSHA, EPA & NFPA standards and codes.

Operation/Maintenance Manuals: A manual specific to each rectifier system is

provided that includes: system/component description, trouble shooting guide,

drawings of system and circuit boards to the component level and unit bill of

materials with recommended spare parts list.

Standard DC Nominal Output Voltages: 125, 250, 500, 600, 750, 1100, 1500,

"low voltage" 28.5, 32 & 40.

Standard Output Regulation: +/- 1% using voltage or current feedback over the

regulated range from 10% to 110% load change and maximum AC line fluctuation of

+/- 10%. Tighter regulation is available per the application, IEEE 421A and Mil

Std. 704E.

Service Factors: 1.15 load continuous at 40E C ambient.1.00 load continuous at 50’ C ambient.1.25 load for two hours at 40’ C ambient.1.50 load for two minutes at 40’ C ambient.

Efficiency: 95% or better at 100% load, 100% volts for convection cooled units.

Power Factor: 95% at 100% load, 100% volts.

Ripple: 6% RMS at 100% volts, into a resistance load for a three pulse SCR-

diode hybrid bridge system, non-filtered output. For applications

requiring lower percentage ripple, or detailed data and definition of

unit output voltage and current ripple parameters contact Kinetics'

factory sales engineering. If rectifier is to be applied powering; DC

chopper circuits, inverters, lasers or DC brushless motors consult

Kinetics' engineering for proper rectifier wave form requirement

46

specifications.

Response: Less than 50 milliseconds. IEEE 421A.

System Protection Features: 600 volt class units have an AC circuit breaker,

under-voltage or shunt circuit breaker trip in units 20 Kw and larger, current

limiting fuses for semi conductors, AC and DC surge suppression network, solid

state current limit and immense overcurrent shut-off of semi-conductor circuitry

and over temperature thermal protection of the transformer and convection aided

type bridge assembly.

Parallel Operation: Kinetics regulated rectifiers have the capacity to operate

on a common DC bus with other rectifiers or motor generator sets. Optional

feature of current balance circuit can be added if desired to have controlled

load sharing with other DC sources.

Transformer Testing: Kinetics manufactured transformers tests include: high

potential, open circuit radio, excitation and short circuit regulation. Tests

to conform to ANSI/IEEE standards C57.12.01 for dry type transformers.

Rectification Testing: Operational feature diagnostics testing of all control

functions, output regulation at no-load and load, percent of output ripple,

system protective feature operational tests, wave form analysis comparison test.

Full current at reduced voltage or full current at full voltage service factor

heat run loading test performed as an option. If service factor testing is

desired, the test must be specifically quoted in Kinetics engineering proposal

of the system to be provided.

Standard Features:

AC Line Protection: Standard voltage units (208, 230, 240, 460, 480, 575 volts,

3 phase, 60 Hz) are equipped with a thermal magnetic molded case power circuit

breaker. Units 20 Kw and larger come standard with an undervoltage trip for

electrical disconnect on the AC input to the rectifier.

Higher voltage units (2300, 4160, 6900, 7200, 13,200, three phase, 60 Hz.) have

47

terminations provided from the rectifier protective trips for interface with AC

switchgear electrical trip circuit. As an option Kinetics offers match and line

unit switchgear units; load break switch and fuse or vacuum contactor.

Isolation Transformer: Kinetics manufactured, specifically designed and rated

for semi-conductor application, industrial duty, dry type isolation transformer.

Service factor to correspond with rectifier system service factor. Convection

cooled with insulation class H (200EC), class F (155EC) operated. Over-

temperature thermal protection against overloads and single phasing provided in

each coil. Thermals interfaced with AC circuit breaker trip (under 600 VAC) or

AC switchgear electrical trip circuit (above 600 VAC). Primary taps of one (1)

5% above and below nominal input voltage.

Rectifier Elements:

- Hermetically sealed, industrial rated in excess of NEMA standards, silicon

rectifier devices in a three phase SCR (3) diode (3) hybrid system.

- Semi-conductor devices are mounted on oversized, corrosion resistant

extruded heatsinks for proper heat dissipation.

- Each semi-conductor will be individual fused with silver sand fast acting

current limiting semi-conductor fuses on the semi-conductors input.

- Semi-conductor peak inverse voltage to be conservatively rated for a given

application. General duty units to have PIV ratings of 3 times the

transformer secondary voltage. Mill duty units to be rated a minimum of 6

times the transformer secondary voltage.

- Thermal over temperature protection is provided on convection aided cooled

rectifier bridge heatsink arms.

-

Free Wheeling or Commutating Diode: Used to reduce the current ripple into a

highly inductive load, such as a motor or generator field.

Surge Suppression: Oversized, semi-conductor, transient surge suppression and

48

R-C dv/dt snubber networks are provided on both the AC and DC output of

rectifier elements. Continuous bleed resistance is provided across the

rectifier output bus for the absorption of voltage surges and "light"

regeneration on the DC bus.

SCR Control Circuitry: Systems incorporate the use of Kinetics' solid state

electronics SCR pulse width modulation, SCR trigger and referencing, firing

circuitry. Circuitry provides adjustable current limiting control and immense-

over-current, firing circuit shutoff, protective circuitry.

DC Output Control: Standard unit has a control potentiometer mounted on the

enclosure door. Option of unit output control from a 4-20 milliamp, 0-10 volt

or computer/microprocessor generated

signal is available. Unit can be provided with a local or remote output control

selection switch.

Cooling: NEMA1 or NEMA3R enclosures are designed and rated for convection

cooling. Transformers are designed and manufactured with the capacity to

operate convection cooled within the unit service factors. The rectifier bridge

assembly may have low CFM fans mounted on the base of the heatsinks to aid in

moving heat from the semiconductors to and out the heatsinks. Air inlet and

outlet filters, wind switches or air ducting are not required.

Enclosures: Indoor operation units are supplied in NEMA1 steel, freestanding,

vented, convection cooled, rugged mill duty enclosures. Components to have

single side access through a hinged full enclosure length door. Enclosures

suitable for fork truck lifting. Standard paint is electro-statically applied

Kinetics blue industrial enamel finish. (Other colors available per

specification). Enclosure types of NEMA3R, 4, 4X, 12 and specific dimensions

are available to meet the application.

Enclosure Grounding: An enclosure grounding lug is provided meeting applicable

codes.

49

Annunciation: Standard unit has DC analog ammeter and voltmeter, power on

indication light, fuse/semi-conductor open indication lights to identify

position of open device (20 Kw and larger), on/off pushbutton and AC circuit

breaker through the door operator. Annunciation is mounted on the enclosure

door. Numerous annunciation options are available to meet the applications

requirements.

Additional Features Available:

1. Customized Enclosures: Kinetics' in-house fabrication department

manufactures NEMA1, 3R, 4, 4X and 12 classification mill duty enclosures.

Fitting systems into a given enclosure footprint dimension or special profile is

available.

1A. Open Panel: Unit can be provided on open panel assemblies for mounting

within an existing installation enclosure or an enclosure provided by others.

Kinetics' in-house fabrication facilities enable Kinetics to offer unit

packaging that remains flexible to space constraints.

2. Strip Heater with Thermostat Control: For environments where condensation

may be a problem (i.e. dockside or hydro-electric generation stations) or units

having voltages of 600 volts and higher, enclosures can be provided with

thermostatically controlled strip heaters.

3. Magnetic Primary Contactor: For application requiring remote actuation of

an AC line connection from pushbutton or other pilot device.

4. DC Output Circuit Breaker: Manual or electrical trip, station or drawout

DC switchgear enclosure can be provided on the output bus of the rectifier.

5. DC Bolted Pressure Switch: Manual or motor operated

no-load operation can be provided to isolate the rectifier off the DC

distribution bus. DC fusing of the switch can be added.

6. Motor Kit: Consists of addition of a loop contactor and field supply to

make a limited voltage range motor drive or combination power supply and reduced

50

voltage starter. Motor drive feature adders such as field rheostats, field

regulators, dynamic braking or slow down and field loss relay are available.

7. Annunciation: Customized meters (digital or analog), alarms, unit status

indication lights, terminal ports for remote annunciation/control,

keypad/digital readout system and remote operation stations are available.

8. Ripple Filter: Output R-C DC ripple filters to meet the application

requirements. For aircraft hanger support application Kinetics offers filtered

systems that meet military standard 704E.

9. 6, 12 & 24 SCR Pulse Bridge Systems: For applications where "lower" DC

output ripple is desired without the use of R-C DC ripple filters and "faster"

regulation response time; consult with Kinetics engineering for a system to meet

the application.

10. Ramp On and/or Off of Output: Linear adjustable time interval ramp

control of rectifier output circuitry.

11. Micro-processor or Computer Interface: Interface ports for unit control

and/or unit status annunciation.

12. Power Factor Control: Monitoring circuit kit, circuitry regulates output

of rectifier based on monitoring of load power factor.

13. Current Balance: Solid State control circuit balances current loading

between other rectifiers or motor generators on a common DC bus network.

14. Extended Voltage or Field Current Range: If an operating range is required

larger than 110% to 80%; Kinetics will provide a system designed to meet the

applications requirements.

ie. For impulse load, such as a steel mill rolling mill, Kinetics offers upward

extended voltage range field forcing of normally 145% of the unit's nominal DC

voltage for one minute. To protect the field from extended over voltage and

burnout, Kinetics offers a field forcing timed interval system trip lockout

circuit.

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15. Regenerative Absorption Protection. For applications where the load has

the ability to overdrive the power source or raise the buss voltage to excessive

electrical parameters a regenerative absorption circuit is required to protect

the rectifier and load. A well established industry and NEMA standard for

specification of capacity is 10% of the rating of the rectifier kilowatts or if

a single motor, 25% of the motor horsepower. Applications such as steel mill

ladle cranes, elevators and rotating inertia machine tools may require larger

capacity units, please consult Kinetics engineering for capacity and duty cycle

sizing assistance.

40. Constant Potential, Diode, Exciter with Multiple EPT Taps

Kinetics model type MVR / CVR

Kinetics manufactures diode rectifiers from 1 to 2000 Kw. Line regulated, diode

rectifiers are the lowest first cost method of providing DC to the field of a

synchronous motor when either voltage adjustment by changing transformer taps or

a full field current capacity rheostat is acceptable. DC voltage adjustment is

100% manual by either adjusting the field rheostat or changing the 5% increment

taps on the power supply's transformer.

When applying a diode rectifier, users should be aware that the field

application panel voltage adjustment rheostat may need regular adjustment to

compensate for changes in AC input voltage variation and the changing resistance

of the motor field as the motor warms to its operational temperature. The need

to adjust the field rheostat as the motor warms and cools can be a nuisance and

add operating man-hour costs. An SCR regulated, Kinetics' model type SVRS, does

not require repeated adjustment and the energy consuming, resistance bleeding to

obtain a voltage drop. The rheostat is eliminated from the system.

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41. KINETICS SYNCHAPP-C

Contactor Type – Brush Type Synchronous Motor Field Application Panel

The KINETICS SYNCHAPP-C is a state-of-the-art "confirmed motor and excitation system status" synchronous

motor field application panel. The panel incorporates the use of solid state sensing of motor field characteristics, micro-

processor sequencing control with micro processor logic protection features and mill duty, electro-mechanical power

circuit contactors to provide a complete motor field application system operating in conjunction with an AC motor

starter and DC power source. The SynchApp-C monitors the output signals from the AC motor starter current

transformers, CT's, and voltage transformers, PT's, providing continuous motor status monitored, fault protection and

operation annunciation.

Kinetics' design & manufacture philosophy of; building a product that is low in maintenance, conservatively rated,

interactive with the production system and provides annunciation and diagnostic feedback the helps to minimize trouble

shooting downtime, are included within every Kinetics SYNCHAPP-C field application panel systems.

Kinetics manufactures regulated and constant potential excitation rectifiers and can provide AC motor starters,

exciters and the application panel within a package system.

For digital annunciation and control with the capacity to place information on a communication network is available

by addition of the KinetSync-SR model.

The solid state logic controls of the application panel sense the synchronous motor rotor starting dynamics; apply

the field excitation DC power and remove the field discharge resistance at the optimum time by the use of a properly

sequenced mill duty DC contactor(s) with overlapping, two normally open and one normally closed, combination

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contact function system to meet the desired application requirements. On motor shut down, the motor field contactors

apply the discharge resistance to the motor field and remove the DC field excitation power source in the proper

overlapping sequence for motor, control and system protection from the fields highly inductive load discharge.

The DC field excitation power for the Kinetics SynchApp-C panel can be provided from a Kinetics regulated rectifier,

Kinetics constant potential diode rectifier, common DC bus or MG set.

The application panel does not come with the field discharge resistor as a standard. A resistor grid is an available

option offered by Kinetics.

An integral part of the Kinetics application panel system is the a micro-processor logic and annunciation system that

provides continuous readout of the motor starting sequence position, motor operation status, availability of excitation

voltage and current, monitoring of motor power factor and starting sequence trip or system fault trip indication. The

cause of a system trip is identified by illumination of a problem identification LED on the system logic micro-processor.

Panels are provided with the provision for remote annunciation interface.

Motor and/or application protection trip functions, particular to a specific installation can be interfaced into the

Kinetics application panel with the addition of an interface trip function / annunciation micro-processor. For ease of

service excitation system trip functions are kept separate from the load or external system trip function. When the

interface micro-processor is added; the trip function is identified with an annunciation LED and one signal is sent to the

application panel logic micro-processor, tripping the motor off line.

A 120 volt, 5 ampere external AC power source is required for the operation of the panels logic micro-processor.

Motor field currents are monitored throughout the starting, running and shut-down sequences to provide continuous

sequence and operational protection and annunciation.

For the maximum protection of the synchronous motor; the Kinetics SynchApp-C panel is a "confirmed motor

status" operating system. The line voltage, current and power factor for the motor and the DC power source voltage and

current are continuously monitored for confirmed proof of the motor and excitation system's operating status. At no time

does the system have "blind" spots of operation or is the field applied with the assumption that the motor has reached

synchronization speed.

The "standard" SynchApp-C logic micro-processor annunciates and trips the motor off line in the event of a system

malfunction:• Exciter or DC field power not available trip.• Locked rotor protection.

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• Proof of field start.• Proof of field discharge resistor current.• Excessive time interval using the squirrel cage rotor protection.• Incomplete sequence protection• Failure of the motor to synchronize protection.• Field loss or low field current protection.• Pull-out-of-synch protection.

A system trip warning horn and horn silence pushbutton comes as a standard feature on all units.

An annunciation test of the logic micro-processor LED indication lights is provided on all units.

Enclosures: Systems can be provided in NEMA1, 3R, 4, 4X and 12 enclosures for floor or wall mounting. Standard

enclosure has a full length, gasketted, hinged door with screw down industrial grade latch. The logic micro-processor is

viewable through a plexiglas view window. All other annunciation and control are door mounted.

Open panels: System can be provided as open 12 ga. electrical panels for mounting within existing enclosures or an

OEM panel with other equipment. Kinetics in house sheet metal fabrication can provide panels to give Kinetics

flexibility to meet the applications specific space constraints.

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42. KINETICS SYNCHAPP-SS

Totally SOLID STATE Brush Type Synchronous Motor Application Panel

With Regulated Excitation Rectifier & KinetSync-SR Digital Annunciation and Logic Module

The KINETICS SYNCHAPP-SS synchronous motor field application unit plus KinetSync-SR digital annunciation &

logic module is a state-of-the-art "confirmed motor and excitation system status system" consisting of an integrated

regulated rectifier and 100% solid state synchronous motor field application panel. The SYNCHAPP-SS exciter /

application panel system incorporates solid state sensing of motor field characteristics, micro-processor sequencing

control and protection via the Kinetics KinetSync-SR digital annuncation and logic module, regulated solid state

rectification with a motor field and discharge resistor engaging and disengaging by means of Kinetics' high peak reverse

voltage blocking capacity semi-conductor switching package.

Crowbar protection: sequencing protection to assure application of the field discharge resistors.

Kinetics' design & manufacture philosophy of; building a product that is low in maintenance, conservatively rated,

interactive with the production system and provides annunciation and diagnostic feedback the helps to minimize trouble

shooting downtime, are included within every Kinetics SYNCHAPP-C field application panel systems.

The SYNCHAPP-SS is designed to operate in conjunction with the AC motor starter. Kinetics can provide a motor

starter system as an available system option.

An integral part of the SYNCHAPP-SS is the highly reliable, field proven, Kinetics SVRS regulated rectifier that is

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designed and rated for the highly inductive load operating parameters of synchronous motor field excitation. For a

detailed specification on the rectifier section of the SYNCHAPP-SS see the model type SVRS description within this

brochure.

The Kinetics excitation regulated rectifier component of the SYNCHAPP-SS system can have the feedback loop

closed on either field current, field voltage, motor power factor, VARs or a remotely supplied signal by other. The mode

of output regulation from the systems SCR rectifier must be selected at the time of order.

The Kinetics SYNCHAPP-SS with KinetSync-SR system monitors the output signals from the AC motor starter

current transformers, CT's, and voltage transformers, PT's, providing continuous motor status monitor, fault protection

and operation annunciation.

The solid state logic circuitry monitoring the motors operational status, in addition to continuously monitoring, the

SYNCHAPP-SS with KinetSync-SR continuously monitors the motor’s status; senses the motor rotor speed and

applies the regulated rectifier output to the motor field at the optimum application point by the use of Kinetics' thyristor

switching package.

For the maximum protection of the synchronous motor; the Kinetics SynchApp-SS with KinetSync-SR excitation

system is a "confirmed motor status" operating system. The line voltage, current and power factor for the motor and the

DC power source voltage and current are continuously monitored for confirmed proof of the motor and excitation

system's operating status. At no time does the system have "blind" spots of operation or is the field applied with the

assumption that the motor has reached synchronization speed.

Motor field currents are monitored throughout the starting, running and shut-down sequences to provide continuous

sequence and operational protection and annunciation.

Motor and/or application protection trip functions, particular to a specific installation can be interfaced into the

Kinetics application panel with the addition of an interface trip function / annunciation micro-processor. For ease of

service excitation system trip functions are kept separate from the load or external system trip function. The KinetSync-

SR provides digital micro-processor logic for monitoring the motors operations status. If a “ trip” function is detected,

the trip function is identified on the liquid crystal display screen, recorded in the history registry and a trip signal is sent

to the motor starter to trip the motor off line.

Control power required: A 120 volt, 5 ampere external AC power source is required for the operation of the panels

logic micro-processor.

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Advantages Of The SYNCHAPP-SS Solid State Field Application System:

* Maintenance demanding electro-mechanical field application

contactors are replaced with a solid state, fast response,

thyristor switching package.

* Solid state switching gives "faster" application or disengaging

of the excitation power to the motor field and application or

disengaging of the field discharge resistance.

* Solid state switching gives "faster"

* Physically smaller area footprint than contactor application panels.

* Lighter weight then contactor type application panels.

* Quieter DB then contactor systems / arc-less operation.

* Cleaner operation - no arcing gases as is associated with power contactors.

* Blackbox field maintenance of system components.

Standard AC input voltages to are available at 208, 240, 480, 575, 2300, 2400, 4,160, 6,900, 7,200, 11,500, 13.2

KV and 13.8 KV. 380 volts at 50 Hertz and 25 Hertz systems are also available.

Standard exciter output voltages are 125 and 250 volts DC. Systems with other then common voltages are available

upon request. Kinetics in-house transformer manufacturing capacity enables Kinetics to offer "non-standard" input and/or

output voltages to meet the applications requirements.

The Synchapp-SS with KinetSync-SR provides the following protective functions as standard:• Exciter DC field power not available trip• Locked rotor protection• Proof of field start• Proof of field/discharge resistor current• Excessive time interval using the squirrel cage rotor protection.• Squirrel cage rotor protection• Incomplete sequence protection• Failure of the motor to synchronize protection• Field loss/low field current protection• Pull-out-of-synch protection

A system trip warning horn and horn silence pushbutton comes as a standard feature on all units.

Annunciation via either a logic micro-processor with LED indication lights or KinetSync-SR. The KinetSync-SR

provides word specific fault detailed on the screen and stored in history registry.

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Enclosures: Systems can be provided in NEMA1, 3R, 4, 4X and 12 enclosures for floor or wall mounting. Standard

enclosure has a full length, gasketted, hinged door with screw down industrial grade latch. The KinetSync-SR module

is most commonly enclosure door mounted. All other annunciation, meters, indication lights and control are also door

mounted.

Open panels: System can be provided as open 12 ga. electrical panels for mounting within existing enclosures or an

OEM panel with other equipment. Kinetics in house sheet metal fabrication can provide panels to give Kinetics

flexibility to meet the applications specific space constraints.

Power field discharge resistors are included as standard with the Synchapp-SS control but can be provided deleted at the

customer’s request.

.

>> Complete synchronous motor rolling mill excitation system for a 12,000 Hp motor. Power factor regulated exciterwith field forcing capacity, solid state field application system, KinetSync-SR annunciation and logic module,discharge resistors plus redundant application circuit to operate from a common DC mill buss.Kinetics is the only on-going and regular manufacturer in the USA with the in-house manufacturing capacity todesign, manufacture and test a system containing the state of the art technology specifically designed andmanufactured for synchronous motors.